Development of a reversible machining method for fabrication of microstructures by using micro-EDM |
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| Authors: | Zilong Peng Zhenlong Wang Yinghuai Dong Hui Chen |
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| Affiliation: | 1. Key Laboratory of Micro-Systems and Micro-Structures Manufacturing (Harbin Institute of Technology), Ministry of Education, Harbin, 150001, China;2. School of Mechatronics Engineering, Harbin Institute of Technology, PO Box 421, Harbin 150001, China;1. Department of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai, India;2. Department of Mechanical Engineering, University of Arkansas, Fayetteville, AR, USA;3. Mechanical and Materials Engineering, University of Nebraska-Lincoln, NE, USA;1. Faculty of Engineering of Bilbao, University of the Basque Country, Alameda de Urquijo s/n, 48013 Bilbao, Spain;2. Faculty of Technical Engineering of Bilbao, University of the Basque Country, Paseo Rafael Moreno “Pitxitxi” 3, 48013 Bilbao, Spain |
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| Abstract: | A new micromachining method for the fabrication of micro-metal structures by using micro-reversible electrical discharge machining (EDM) was investigated. The reversible machining combines the micro-EDM deposition process with the selective removal process, which provides the ability of depositing or removing metal material using the same micro-EDM machining system. From the discharge mechanism of micro-EDM, the process conditions of micro-EDM deposition were analyzed firstly. Using the brass and steel materials as a tool electrode, the micro-cylinders with 200 μm in diameter and height-to-diameter ratio of more than 5 were deposited on a high-speed steel surface. Then the machining procedure was transformed easily from deposition to selective removal process by switching the process conditions. Different removal strategies including micro-EDM drilling and micro-EDM milling were used in the machining. Micro-holes with 80 μm in diameter are drilled successfully in the radial direction of the deposited micro-steel cylinder. Also, a brass square column with 70 μm in side length and 750 μm in height, and a micro-cylinder with 135 μm in diameter and 1445 μm in height are obtained by using micro-EDM milling. Finally, the characteristics of the deposited material were analyzed. The results show that the material components of a deposited micro-cylinder are almost the same as those of the tool electrode, and the metallurgical bonding has been formed on the interface. In addition, the Vickers-hardness of 454Hv of the steel deposited material is higher when compared to the hardness of 200Hv of the raw steel electrode. |
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